Application Note

System-Based Testing of Fast Motor Bus Transfer

Systems

Authors
Benjamin Mößlang and Florian Fischer | [email protected]

Date
Oct 01, 2022

Related OMICRON Product

CMC - RelaySimTest

Application Area
Motor Bus Transfer

Keywords
RelaySimTest, System Testing, Fast Motor Bus Transfer, High-speed Motor Bus Transfer, Induction
Machine, System-based Testing

Version
V1.0

Document ID
ANS_22004_ENU

Abstract
There are specific requirements for operating motors in critical processes, such as in the petrochemical
industry and but also in power plants. Outages of these machines can be very costly. If a fault occurs in the
grid connection of such critical machines, it is necessary to switch to a reserve feed to ensure that the
process can continue. Switching is accomplished by high-speed bus transfer systems (MBTS). Testing these
systems is not trivial since the interaction between the motors and the system is crucial. This often poses
problems because it requires a transient simulation. This application note shows how to use RelaySimTest
to create and execute test scenarios for lab engineering, factory acceptance, and commissioning testing.
 General information

OMICRON electronics GmbH, including all international branch offices, is henceforth referred to as
OMICRON.
The product information, specifications, and technical data embodied in this Application Note represent the
technical status at the time of writing and are subject to change without prior notice.
We have done our best to ensure that the information given in this Application Note is useful, accurate and
entirely reliable. However, OMICRON does not assume responsibility for any inaccuracies which may be
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OMICRON translates this Application Note from the source language English into a number of other
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© OMICRON 2022. All rights reserved. This Application Note is a publication of OMICRON.

© OMICRON 2022 Page 2 of 22

 Table of contents

1 Safety instructions ................................................................................................................................4

2 About this application note ..................................................................................................................5
2.1 General requirements .....................................................................................................................5
2.2 What this application note describes ..............................................................................................5
2.3 Template .........................................................................................................................................5
3 High-speed motor bus transfer systems ............................................................................................6
3.1 General ...........................................................................................................................................6
4 System under test .................................................................................................................................9
5 Test Set Configuration ....................................................................................................................... 12
6 Suitable test cases ............................................................................................................................. 14
6.1 General ........................................................................................................................................ 14
6.2 Wiring check with the Interactive System Simulation .................................................................. 15
6.3 Transfer Test Cases .................................................................................................................... 16
6.4 Fault on the busbar or at the motors ........................................................................................... 19
7 List of literature................................................................................................................................... 21

© OMICRON 2022 Page 3 of 22

1 Safety instructions
This Application Note may only be used in conjunction with the relevant product manuals which contain all
safety instructions. The user is fully responsible for any application that makes use of OMICRON products.
Instructions are always characterized by a  symbol, even if they are included in a safety instruction.

NOTICE

Possible equipment damage or data loss

 Carefully read and understand the content of this Application Note as well as the manuals for the
systems involved before operating them.
 Please contact OMICRON support if you have any questions or doubts regarding the safety or
operating instructions.
 Follow each instruction listed in the manuals, especially the safety instructions, since this is the
only way to avoid the danger that can occur when working on high voltage or high current
systems.
 Only use the equipment according to its intended purpose to guarantee safe operation.
 Existing national safety standards for accident prevention and environmental protection may
supplement the equipment’s manual.
 Before starting a test always make sure that the test signals are suitable for the system that
you’re testing.

Only experienced and competent professionals that are trained for working in high voltage or high current
environments may implement this Application Note. The following qualifications are also required:
• Authorization for working in environments involving energy generation, transmission, or distribution,
and familiarity with the approved operating practices for such environments.
• Familiarity with the five safety rules.
• Knowledgeable and proficient when working with RelaySimTest and the CMC test sets.

© OMICRON 2022 Page 4 of 22

2 About this application note

2.1 General requirements

Before you get started with this application note, read the “Getting Started” manual [1] of RelaySimTest.
Please make sure that you also have a good knowledge about the CMC test system.

2.2 What this application note describes

This application note describes how high-speed motor bus transfer systems can be tested using
RelaySimTest. Therefore it shows the following content:
1. Principals of a motor bus transfer system
2. Test case design with RelaySimTest
This application note is not a complete guide for testing motor bus transfer systems, it is meant to show the
capabilities of RelaySimTest and OMICRON’s test sets in the field of testing busbar transfer systems.

2.3 Template

For this application note a corresponding template is installed with the setup of RelaySimTest.

The template Motor Bus Transfer.rstt contains the same system under test and test cases described in the
application note.

© OMICRON 2022 Page 5 of 22

3 High-speed motor bus transfer systems

3.1 General

In order to keep critical processes in operation, reserve infeeds are included in the planning phase for
motors operating such a critical process. If the main supply can no longer supply the motors, for example
due to a fault in the upstream network, the reserve supply must be used. Since interruptions of only a few
seconds can be critical for the continued operation of the motors and processes, fast-switching devices must
be incorporated. In the event of a fault, these high-speed transfer devices ensure that the supply to the
motor busbar is switched over safely. To switch over from one supply to another, the voltage vectors of the
busbar and the reserve infeed must not be too far apart in amplitude and phase angle. Otherwise, when
switching over, extreme stresses on the motors, couplings and other equipment can occur. Figure 1 shows
possible configurations for systems with a transfer relay. For this application note, a system like the one
shown in Figure 1 (a) is used.

(a) (b)

Figure 1 - Possible configurations

In order to perform safe switching, the device compares the voltage vector on the busbar and the reserve
feeder. If the supply to the busbar is lost, the motors run down, the speed is reduced, and the voltage drops.
This is shown in Figure 2. Figure 3 shows the vector diagram, with the vector on the busbar moving away.
The amplitude and frequency of 𝑉𝑉𝐵𝐵𝐵𝐵𝐵𝐵 is decaying, and the vector of 𝑉𝑉𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼2 remains constant. As already
mentioned, switching on may only take place if the two vectors are close enough to each other (in amplitude
and phase).

© OMICRON 2022 Page 6 of 22

 (a)

(b)

Figure 2 - Induction machine coast down. (a) Speed, (b) Motor terminal voltage

Figure 3 - Induction machine coast down vector diagram

For this purpose, such devices can resort to four basic transfer modes:
1. Fast-transfer
Here the switching takes place as quickly as possible before the vectors drift apart.
2. In-Phase transfer
In this switching mode the transfer happens when the phase angle of the motor bus is again in
phase with the infeed.
3. Residual voltage transfer
If the amplitude falls below a certain threshold, switching is allowed regardless of the phase angle.
4. Time delay transfer
This mode assumes that after a certain amount of time, the voltage at a busbar is safe enough be
connected, regardless of the amplitude and phase angle.

Figure 4 illustrates the different transfer modes. Zone 1 corresponds to the fast-transfer, Zone 2 to the In-
Phase transfer and Zone 3 to the Residual transfer.

© OMICRON 2022 Page 7 of 22

 Figure 4 - Illustration of transfer modes. Source: IEEE Guide for AC Motor Protection [2]

© OMICRON 2022 Page 8 of 22

4 System under test
Figure 5 shows the system under test used in this application note. The topology is a single busbar system
with a main infeed Infeed 1 and a backup infeed Infeed 2. Connected to the busbar are two identical
induction motors with 𝑃𝑃𝑚𝑚𝑚𝑚𝑚𝑚ℎ = 630 𝑘𝑘𝑘𝑘 each and an additional static load with 𝑆𝑆𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 = 450 𝑘𝑘𝑘𝑘𝑘𝑘. An ABB
SUE 3000 transfer relay is used as the high-speed transfer relay, this device is incorporated into the system
under test as a device. The simulated devices Infeed Relay 1, Infeed Relay 2 and the Busbar/Motor Relay
are used to trigger or block the transfer. Ideally these three devices would not be simulated but would be real
devices in the test setup. This would make more in-depth coverage of the test possible.

Figure 5 - System under test

The behavior of the motors is essential to the operation of these transfer systems. Therefore, it is crucial to
incorporate them into the simulation. RelaySimTest’s induction motor model can easily be defined by data
from the nameplate and the datasheet. Figure 6 shows the dialogue for defining the induction motor.
The voltage transformers on the infeeds and the busbar are measuring the voltage between phases L1 and
L2 and the current transformers are measuring the currents of phase L1. The transfer relay only needs these
single-phase signals. Furthermore, the transfer relay takes the auxiliary contacts of the breakers at the
infeeds as an input. The transfer trigger signals from both feeder relays and the blocking signal from the
busbar/motor relay is also an input for the transfer relay.
The timing of the circuit breakers is also an important factor. Some manufacturers have high-speed breakers
that allow very fast transfers. Figure 7 shows the settings of the circuit breaker at infeed 2. Figure 8 shows
the configuration of the CB auxiliary contact simulation.

© OMICRON 2022 Page 9 of 22

 Figure 6 - Edit Motor Data Dialogue

Figure 7 - Circuit Breaker Settings

© OMICRON 2022 Page 10 of 22

 Figure 8 - CB Auxiliary Contact Simulation

© OMICRON 2022 Page 11 of 22

5 Test Set Configuration
Figure 9 shows the test set configuration overview in RelaySimTest. Two CMC test sets are used for the
tests in this application note.

Figure 9 - Test Set Configuration

The relays are connected via an Ethernet network and time synchronized via Local Sync. In this
synchronization mode the connected test sets synchronize each other. This can be used for test setups with
multiple local CMCs. The RelaySimTest help document provides further information about Local Sync.

Figure 10 - Local Sync

The configuration of the analog signals is displayed for one CMC 430 as shown in Figure 11. The voltage
amplifiers are operated in the single-phase mode and the current outputs are operated in the high-current
mode. The binary signals are configured as shown in Figure 12.

© OMICRON 2022 Page 12 of 22

 Figure 11 - Configuration of analog outputs

Figure 12 - Configuration of binary signals

© OMICRON 2022 Page 13 of 22

6 Suitable test cases

6.1 General

A few things need to be considered before running these tests. The relay blocks a new transfer for 5
seconds after a transfer. Therefore, a pause of 5 seconds in between the test steps and Iterative Closed-
Loop (ICL) iterations are set in the test case settings. Figure 13 shows how this is done. The relay also
needs 2.5 seconds of pre-fault time, to allow the relay to synchronize with the signals.

Figure 13 - Test Case Settings

© OMICRON 2022 Page 14 of 22

6.2 Wiring check with the Interactive System Simulation

The Interactive System Simulation is used to check the wiring. This test case type can be added in the Test
Manager via the Add Test Case dialogue shown in Figure 14. First the amplitudes of all infeeds are set to
unbalanced and the breaker reaction is suppressed. The turquoise rectangles and arrows in Figure 15
indicate these commands. By doing this, the amplitudes of the 3 phase voltages of all the infeed are set
unequally: 𝑉𝑉𝐿𝐿1−𝑁𝑁 = 1 𝑝𝑝. 𝑢𝑢., 𝑉𝑉𝐿𝐿2−𝑁𝑁 = 0.95 𝑝𝑝. 𝑢𝑢. and 𝑉𝑉𝐿𝐿3−𝑁𝑁 = 0.9 𝑝𝑝. 𝑢𝑢.. This generates currents and voltages at the
measuring points that are different from each other. They can be distinguished easily and the correct wiring
can be checked. The suppression of the breaker reaction is activated because during the wiring check the
unbalanced system conditions, or even applied faults, would lead to a trip by the protection system and the
Interactive System Simulation would open the breaker accordingly. Therefore, the currents and voltages
would be 0. In summary, an ideal wiring test for a protection test should be performed with the Interactive
System Simulation because all the wiring for the entire protection system can be tested as a whole, making it
faster and more efficient. The orange rectangle highlights the live monitor. The readings from the relay can
be compared to the values in the live monitor.

Figure 14 - Add Test Case Dialogue

© OMICRON 2022 Page 15 of 22

 Figure 15 - Wiring Check with Interactive System Simulation

6.3 Transfer Test Cases

A set of test cases can be defined with the pre-conditions outlined in chapter 6.1. Figure 16 shows
RelaySimTest’s Test Manager with test cases. Two groups are defined that test the transfer of the relay
under different conditions. The test case Transfer 1 -> 2, 1-phase fault is explained.

Figure 16 - Test Manager

In test case Transfer 1 -> 2, 1-phase fault a L1-N fault on feeder 1 occurs. The fault has a fault resistance to
mimic a fault on the feeding line.
According to the ANSI/NEMA Standard C50.41-2012 the “[…]test conditions should account for any phase
angle difference between the incoming and running power supplies.” [3]
Therefore, the phase angle of infeed 2 is varied between -30° and +30° over multiple test steps.
© OMICRON 2022 Page 16 of 22
 Figure 17 - Transfer 1 -> 2, 1-phase fault

The fault occurs at 2.5 s of the test and after a few milliseconds the simulated binary signal from Infeed
Relay 1 issues a transfer trigger to the transfer relay.

© OMICRON 2022 Page 17 of 22

 Figure 18 - Snippet of the test case's time signal view

An important function for these test cases is RelaySimTest’s Iterative Closed-Loop (ICL) function. This
function allows you to iteratively build the test sequence for this test case. OMICRON’s RelaySimTest
Getting Started Manual explains this function in detail.[1]

Figure 19 - Iterative Closed-Loop

Figure 20 shows the table with the test steps of the measurement Transfer 1 -> 2. This measurement
measures the time between the fault inception and the closing of the circuit breaker 2. The transfer relay
could perform a fast-transfer for test steps 2 to 6. For test step 1 and 7 the relay could only issue an in-
phase transfer, because the voltage vectors were too far apart.

Figure 20 - Test Steps

The Vary Parameter Dialogue in RelaySimTest allows the user to easily create multiple test steps with varied
parameters, e.g.: the fault resistance or infeed parameters. With this level of functionality multiple test
conditions can be created to test the transfer system in detail. The number of cases used for this application
note has been reduced for clarity. Figure 21 shows the dialogue. Motor load events can also be used to
adapt the motor’s mechanical load.

© OMICRON 2022 Page 18 of 22

 Figure 21 - Vary Parameter Dialogue

6.4 Fault at the busbar or the motors

Another important test case to consider is the case of a fault at the busbar or the motors. If a fault occurs on
these parts of the system, the transfer relay should not initiate a transfer, since this won’t clear the fault and
the fault would still be fed by the other infeed. The busbar or motor protection system is responsible for
clearing the fault and blocking the transfer. Usually, these protection devices will issue a blocking signal to
the transfer relay. In this application note and the corresponding template, the blocking signal comes from a
simulated device. Figure 22 and Figure 23 show information from the test case. The feeder relay detects an
under-voltage and issues a transfer command to the transfer relay, but the busbar protection relay issues a
blocking signal to the transfer relay because the fault is detected at the busbar. Therefore, the transfer relay
should not initiate a transfer.
In addition to this test case, faults at the motors could also be simulated. In these cases, the transfer relay
should not initiate a transfer either.

© OMICRON 2022 Page 19 of 22

 Figure 22 - Fault on busbar

Figure 23 - Simulated binary signals

© OMICRON 2022 Page 20 of 22

7 List of literature
[1] “RelaySimTest Getting Started Manual”, OMICRON Electronics GmbH, Klaus, Austria 2021.
[2] "IEEE Guide for AC Motor Protection," in IEEE Std C37.96-2012 (Revision of IEEE Std C37.96-2000) ,
vol., no., pp.1-160, 20 Feb. 2013, doi: 10.1109/IEEESTD.2013.6468048.
[3] NEMA, Rosslyn, VA, USA, ANSI/NEMA C50.41-2012, "Polyphase Induction Motors for Power
Generating Stations".

© OMICRON 2022 Page 21 of 22

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